Power interconnecting part for electrical rotating machine

ABSTRACT

A power interconnection piece for a rotary electrical machine, wherein the power interconnection piece comprises at least one power track provided with electrical power terminals intended to cooperate with a power track of at least one electronic module so as to distribute electrical power to the electronic module, the electronic module being integrated on the rotary electrical machine and wherein the power interconnection piece comprises a base plate made from insulating material that at least partially overmolds the power track.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to PCT Application PCT/FR2006/050362filed Apr. 20, 2006 and also to French Application No. 0505501 filed May31, 2005, which applications are incorporated herein by reference andmade a part hereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns a power interconnection piece for a rotaryelectrical machine.

The present invention applies to any type of polyphase rotary electricalmachine, synchronous or asynchronous, such as alternators or alternatorstarters, and also whether it is a case of electrical machines for motorvehicles and driven for example by belt, with cooling by air, liquid orany other solution that can be envisaged.

2. Description of the Related Art

In a motor vehicle comprising a thermal engine and a rotary electricalmachine such as an alternator starter, such an electrical machinecomprises for example, non-limitatively:

-   -   a rotor comprising a field winding into which an excitation        current is brought; and    -   a stator comprising a polyphase winding.

The alternator starter functions in motor mode or in generator mode. Itis a so-called reversible machine.

In generator or alternator mode, the machine converts a rotationmovement of the rotor driven by the thermal engine of the vehicle intoan electric current induced in the phases of the stator. In this case, abridge rectifier connected to the phases of the stator rectifies thesinusoidal induced current into a DC current in order to supplyconsumers on the vehicle such as a battery.

On the other hand, in motor mode, the electric machine serves as anelectric motor for rotating, via the shaft of the rotor, the thermalengine of the vehicle. It converts electrical energy into mechanicalenergy. In this case, an inverter converts a DC current coming from thebattery into an alternating current for supplying the phases of thestator in order to rotate the rotor.

Control signals are used to determine the operating mode of the rotaryelectrical machine (motor mode or generator mode).

Finally, it is necessary to supply all the electronic components withpower.

In the document DE 102004007395 A1, use is made of the electroniccomponents that are inside an external peripheral band. These componentscomprise power ends that are also inside the band. The band comprisesinternal partitions in which metal power interconnection tracks aremolded on with signal tracks. They are superimposed on one another.These power tracks connect the components via their power ends to thebattery so as to supply them. The band is positioned on the rear bearingof the machine. This solution proves to be problematic because firstlyof the complex design of the superimposed tracks and secondly thecross-sections of power interconnection tracks that are too smallcompared with the current necessary, around 150 A in alternator mode and600A on starting, for the application of a starter or alternatorstarter, so that the said tracks reach an excessively high temperature.

SUMMARY OF THE INVENTION

Thus an object of the present invention is to propose a powerinterconnection piece for a rotary electrical machine that can easily beintegrated on a rotary electrical machine and that can have sufficientlylarge conductors to withstand the currents that pass through them.

To this end, according to a first object of the present invention, thepower interconnection piece comprises at least one power track providedwith power electrical terminals intended to cooperate with a power trackof at least one electronic module so as to distribute electrical powerto the said module, the said module being integrated on the saidmachine.

Thus, as will be seen in detail below, having a power interconnectionpiece comprising electrical terminals intended to cooperate with theelectronic components makes it possible to have a power interconnectionpiece independent of the said modules and to stack the said piece in aplane different from that used by the said electronic components. Thusthis avoids problems of overmolding of the tracks. Moreover, offsettingthe interconnections on a plane different from the electronic componentsreleases more surface area for the electronic modules and therefore forthe electronic components and also for the power interconnection tracks.Thus there is a larger cross-section of power tracks so as to conveymore power. The interconnection tracks are thus defined independently ofthe space taken up by the electronic components on the machine.

According to non-limitative preferential embodiments, the powerinterconnection piece that is the object of the invention has theadditional characteristics stated below.

-   -   it comprises a base plate made from insulating material that        moulds on the power interconnection track;    -   it is configured so as to be placed on a plane different from        that of the electronic module;    -   it is independent of the electronic module;    -   the power terminals extend towards the external periphery of the        piece;    -   the power terminals are not molded on;    -   the power terminals comprise curved free ends;    -   a power track is flat;    -   it comprises at least one positive power interconnection track        and at least one negative interconnection track;    -   it is configured so as to be disposed above the electronic        module;    -   the power tracks are interleaved;    -   the tracks are concentric;    -   the power tracks are on the same plane;    -   the power tracks are not superimposed so as to allow electrical        connection with tracks on a cover;    -   the respective power terminals of the positive and negative        power tracks are intended to cooperate respectively with        positive and negative tracks of an electronic module;    -   there exist at least one positive power terminal and at least        one negative power terminal for one electronic module;    -   there exist a single positive power terminal and a single        negative power terminal for one electronic module;    -   the base plate comprises at least one recess for an electrical        connection of a power interconnection track with a cover;    -   it also comprises fixing devices for fixing to an electronic        module, the devices extending radially on the external periphery        of the piece;    -   electrical terminals are flexible;    -   it also comprises devices for pre-assembly on a signal        interconnection piece, the signal piece conveying control        signals between electronic modules;    -   it also comprises inserts for receiving fixing means for fixing        to the machine;    -   it also comprises a mechanical stop disposed on the outside        diameter of the piece;    -   it also comprises support devices for supporting the piece on a        dissipator of the rotary electrical machine during assembly;    -   it comprises a central recess for the insertion of a brush        holder;    -   it is configured so as to be placed on the bottom face of a        dissipator;    -   it also comprises at least one insert for receiving a hollow        rivet and effecting a pre-assembly with an electronic module and        a signal interconnection piece and a dissipator;    -   it also comprises means of protecting stator phases of the        rotary electrical machine;    -   it also comprises means of positioning on the bearing of the        rotary electrical machine, the means extending over a bottom        face of the piece;    -   it also comprises at least one force stay for axial deformation        of the piece;    -   the force stay has a greater height than the insert;    -   it also comprises devices for positioning the piece on a        dissipator of the rotary electrical machine;    -   it also comprises a metal insert so as to effect an electrical        connection with the negative power track;    -   the power interconnection terminals issue from a positive power        track;    -   the electrical interconnection terminals are axial tongues        projecting beyond the top face of the piece;    -   it also comprises means of protecting the positive power        interconnection terminals;    -   it also comprises a power connector in which positive and        negative power tracks are inserted in a visible fashion;    -   it also comprises a terminal for mechanical connection to a        client connector;    -   it also comprises a mechanical connection orifice for preventing        transmission of the mechanical stresses on overmolding when the        client power connector is fixed to the connecting terminal;    -   it also comprises a collar intended to cover air outlet openings        in the bearing of the rotary electrical machine so as to guide        the outlet air and attenuate any looping of air;    -   it is placed on an electronic modules plus signal        interconnection piece plus dissipator assembly, the signal piece        conveying control signals between the various electronic        modules, and the assembly being disposed on a bearing of the        rotary electrical machine;    -   it is placed on a face of a dissipator opposite to that on which        there is disposed an electronic modules plus signal        interconnection piece assembly, the signal piece conveying        control signals between the various electronic modules, the        whole being placed on a bearing of the rotary electrical        machine;    -   it is fixed to an attached dissipator; and    -   it forms with the electronic modules plus dissipator plus signal        interconnection piece assembly an independent electronic        sub-assembly of a bearing of the machine.

Other characteristics and advantages of the present invention willemerge from the following description. This is purely illustrative andmust be read with regard to the accompanying drawings, given by way ofnon-limitative examples.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A depicts the first embodiment of an electronic module accordingto the invention;

FIG. 1B depicts the module of FIG. 1A in a view from below;

FIG. 1C is a view without overmolding of the module of FIG. 1A;

FIG. 1D is the view of FIG. 1C with hard-wired connections of theelectronic components of the electronic module;

FIG. 2A is a first variant of the first embodiment of FIG. 1A;

FIG. 2B is a view from below of the module of FIG. 2A;

FIG. 2C is the view of FIG. 2A with hard-wired connections of theelectronic components of the electronic module;

FIG. 2D is a second variant of the first embodiment of FIG. 2A;

FIG. 3A shows a second embodiment of an electronic module according tothe invention;

FIG. 3B is a view from below of the module of FIG. 3A;

FIG. 3C is a view without overmolding of the module of FIG. 3A;

FIG. 3D is a variant of the second embodiment of FIG. 3A;

FIG. 3E is the view of FIG. 3D with hard-wired connections of theelectronic components of the electronic module;

FIG. 4A is a third embodiment of the electronic module according to theinvention;

FIG. 4B is a view from below of the module of FIG. 4A;

FIG. 4C is a view without overmolding of the module of FIG. 4A;

FIG. 4D is a view in section without overmolding of the module of FIG.4A including a support plate;

FIG. 4E is the view of FIG. 4C with hard-wired connections of theelectronic components of the electronic module;

FIG. 5A is a variant of the third embodiment of FIG. 4A;

FIG. 5B is a view from below of the module of FIG. 5A;

FIG. 5C is a first view from above without overmolding of the module ofFIG. 5C;

FIG. 5D is a second view from below without overmolding of the module ofFIG. 5A;

FIG. 5E is a third view from above without pre-molding and withoutovermolding of the module of FIG. 5A;

FIG. 5F is a fourth view from below without pre-molding and withoutovermolding of the module of FIG. 5B;

FIG. 6 depicts a first embodiment of a dissipator bearing intended toreceive a module of FIGS. 1A and 2A;

FIG. 7 depicts a second embodiment of a dissipator bearing intended toreceive a module of FIG. 3A;

FIG. 8A depicts a first embodiment of a dissipator intended to receive amodule of FIGS. 4A and 5A;

FIG. 8B is a view from below of the dissipator of FIG. 8A;

FIG. 8C is a view in section of FIG. 8B;

FIG. 8D shows an axial air flow and a radial air flow in the dissipatorof FIG. 8B;

FIG. 9A depicts a first embodiment of a signal interconnection pieceintended to be placed on a module of FIGS. 1A and 2A;

FIG. 9B is a view from below of the piece of FIG. 9A;

FIG. 9C is a view without overmolding of the piece of FIG. 9A;

FIG. 10A depicts a second embodiment of a signal interconnection pieceintended to be placed on a module of FIG. 3A;

FIG. 10B is a view from below of the signal interconnection piece ofFIG. 10A;

FIG. 10C is a view without overmolding of the signal interconnectionpiece of FIG. 10A;

FIG. 11A depicts a third embodiment of a signal interconnection pieceintended to be placed on a module of FIGS. 4A and 5A;

FIG. 11B is a view from below of the signal interconnection piece ofFIG. 11A;

FIG. 11C is another view from above of the signal interconnection pieceof FIG. 11A;

FIG. 11D is a view without overmolding of the signal interconnectionpiece of FIG. 11A;

FIG. 12A shows a first embodiment of a power interconnection pieceintended to be in contact with a module of FIGS. 1A and 2A and to besituated above the signal interconnection piece of FIG. 9A;

FIG. 12B is a view from below of the piece of FIG. 12A;

FIG. 12C is a view without overmolding of the piece of FIG. 12A;

FIG. 13A depicts a second embodiment of a power interconnection pieceintended to be in contact with a module of FIG. 3A and to be situatedabove the signal interconnection piece of FIG. 10A;

FIG. 13B is a view from below of the piece of FIG. 13A;

FIG. 13C is a view without overmolding of the piece of FIG. 13A;

FIG. 14A shows a third embodiment of a power interconnection pieceintended to receive a dissipator of FIG. 8A;

FIG. 14B is a view from below of the piece of FIG. 14A;

FIG. 14C is a view without of the overmolding of the piece of FIG. 14A;

FIG. 14D is a view of the piece of FIG. 14A including a collar;

FIG. 14E is a view of the piece of FIG. 14D on a dissipator bearing;

FIG. 15A is a first embodiment of a cover intended to be situated on topof the power piece of FIG. 12A;

FIG. 15B is a view from above of the cover of FIG. 15A;

FIG. 15C is a side view of the cover of FIG. 15A;

FIG. 16 is a second embodiment of a cover intended to be situated abovethe power piece of FIG. 13;

FIG. 17A is a third embodiment of a cover intended to be situated on topof the signal interconnection piece of FIG. 11A;

FIG. 17B is a view from above of the cover of FIG. 17A;

FIG. 18 depicts a mounting of an electronic module of FIGS. 1A and 2A ona dissipator bearing;

FIG. 19 depicts a mounting of a signal interconnection piece of FIG. 9on the dissipator bearing/modules assembly of FIG. 18;

FIG. 20 depicts a mounting of the power interconnection part of FIG. 12Aon the dissipator bearing/module/signal interconnection piece assemblyof FIG. 19;

FIG. 21 depicts the arrangement of FIG. 20 with a cover in partialcross-section;

FIG. 22 is a complete view of the arrangement according to FIG. 21 withthe cover in place, showing a positioning of the cover with respect to amodule;

FIG. 23 depicts a mounting of an electronic module of FIG. 3A on adissipator bearing;

FIG. 24 depicts a mounting of the signal interconnection part of FIG.10A on the dissipator bearing/modules assembly of FIG. 23;

FIG. 25 depicts a mounting of the power interconnection part of FIG. 12Aon the dissipator bearing/module/signal interconnection piece assemblyof FIG. 24;

FIG. 26 depicts the arrangement of FIG. 25 with a cover in partialcross-section;

FIG. 27A depicts a mounting of the modules of FIG. 4A on a dissipator;

FIG. 27B depicts a mounting of the power interconnection piece of FIG.14A on a dissipater;

FIG. 28 depicts a mounting of the power interconnection piece of FIG.14A on the dissipator/modules assembly of FIG. 27A;

FIG. 29 depicts a mounting of the signal interconnection piece on theassembly of FIG. 28;

FIG. 30A is an assembling of the assembly of FIG. 29 on a bearing;

FIG. 30B is a section along a plane X-Y of FIG. 30A of the assembledpower interconnection piece of FIG. 14A; and

FIG. 30C depicts a bearing on which the assembly of FIG. 29 isassembled.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

It should be noted that, in the remainder of the description, thediameter of a bearing of the machine without fixing lug is defined asthe outside diameter of the machine.

Electronic Module

It should be noted that an electronic module, in the context of theinvention, is a set of electronic components that are disposed in ahousing and comprises connection elements accessible from the outsidefor its functioning, these elements making it possible to transmitcontrol and/or power signals.

FIG. 1A depicts a first non-limitative embodiment of an electronicmodule 10 according to the invention.

The electronic module 10 comprises:

-   -   a housing 101;    -   electronic components 102 located in a central zone 1021 covered        with a protective gel such as a gel of the silicone or epoxy        resin type, and a protective plastic cover;    -   electrical conductors 103 (B+), 104 (B−);    -   signal connection elements 106; and    -   fixing points 108.

In addition, the electronic module 10 comprises, as indicated on theview from below in FIG. 1B:

-   -   means 109 of positioning the electronic module 10 on a        dissipator bearing.

The various elements of the electronic module 10 are described below.

The housing 101 is made from electrically insulating material.Preferably, the housing has a substantially triangular basic shape andtherefore has at least three lateral faces and one top face and onebottom face. This shape will make it possible to use a maximum amount ofsurface area on the cylindrical rear of the machine, and this in anoptimum fashion.

Moreover, preferentially, one of the faces of the electronic module 10is an arc of a circle. This is appropriate to the general shape of themachine.

Naturally it would be possible to use other shapes, such as asubstantially rectangular shape.

The electrical conductors 103 (B+), 104 (B−) convey a current comingfrom the battery through the electronic elements.

In a preferential embodiment, the electrical conductors 103, 104 are twopower connection tracks, the ends of which are disposed on the externalperiphery of the module. Preferentially, the tracks are made fromcopper.

Thus, unlike an architecture in which the power necessary for eachmodule passes through all the modules or in which an electronic powercard is situated in a housing separate from the machine, thisconfiguration has the following advantages:

-   -   this allows a salt spray to flow towards the outside of the        machine instead of banking up at the center of the machine,        which prevents corrosion of the tracks by the salt spray;    -   there is less heating in the modules since the power necessary        for a module passes only through the module;    -   the welds on the ends of the tracks are carried out on a single        radius, which makes it possible to automate the welding better;        and    -   this also allows balancing of the current in the modules because        each module is supplied independently, i.e. they are supplied in        parallel.

In a first variant of this embodiment, the electrical conductors 103,104 extend in a plane parallel to that along which the block ofelectronic elements extends. This allows laser welding axial withrespect to the axis of the machine.

In a second variant, the tracks extend along two planes parallel to eachother and parallel to the plane of the block of electronic elements.

It should be noted that track means a cropped metal sheet formed from ametal such as copper.

The signal connection elements 106, called signal connections, conveycontrol signals for controlling the electronic components 102. They thusallow the sending and reception of information necessary for controllingthe inverter arm (motor mode) and/or the arm of the bridge rectifier(generator mode). They afford connection with a signal plate (describedbelow).

In a first preferential embodiment, these signal connection elements 106comprise a first series of signal tongues 106 a and are aligned on oneof the lateral faces of the triangular housing of the module. Thus theaxes of these signal tongues 106 a are in the same plane P1perpendicular to the bottom face of the module, the plane passingessentially through the rotor rotation axis AX.

This alignment makes it possible to carry out linear tongue welding,which limits the time needed for the manufacturing method, called the“process”, and the size. This configuration has the advantage of having,for the signal interconnection piece, a signal track cut in one go,unlike another configuration in which the signal tracks overlap. It willbe noted that, if the tongues are offset towards the inside of themodule, i.e. if the plane does not pass through the rotation axis, thespace for the electronic components 102 is reduced, and otherwise thespace for the other modules is reduced.

Fixing means 108, represented here by orifices, are intended tofacilitate the holding of the module on the electrical machine by meansof studs 113 or screws etc, or any appropriate fixing means.

The means 109 of positioning the electronic module 10 on a dissipatorbearing or dissipator are here two in number 109 a, 109 b as illustratedin FIG. 1B, which are on the bottom face of the module, close to twoopposite edges. In the example, these are pins situated on each side ofthe electronic components 102. They are here spaced at a maximum, whichlimits positioning errors.

In addition, preferentially, the electronic module 10 also comprises, asillustrated in FIG. 2A:

means 107 of protecting the signal connection element 106, facilitatingthe positioning of a cover (described below).

In addition, preferentially, the electronic module 10 also comprises, asillustrated in FIG. 1A:

a phase track 105 connecting the module to a phase of the stator.

In a preferential embodiment, the phase track 105 has an end 105 z thatcomprises a hook 105 cr and makes it possible to connect thereto, bywelding, brazing or any other suitable method, a phase wire or phasetongue coming from the stator of the electrical machine. In the exampledepicted in FIG. 1A, the end 105 z is perpendicular to the track, i.e.to the bottom face, and is situated below the plane; it extendsdownwards. Thus this allows a reduction in the length of the phase wireof the stator and involves a radial weld. In addition, the end 105 z ofthe phase track 105 is situated on the external circumference of themodule, which facilitates the connection with a phase of the stator. Inaddition, preferentially, the end 105 z of the phase track 105 is placedbetween two electrical conductors 103, 104.

This optimizes the “wire bounding” hard-wired electrical connectionsbetween the transistor electronic components and the tracks, inparticular their length, and this makes it possible to avoid overlappingof tracks. In addition, preferentially, the end of the phase track 105is situated in line with a phase output of the stator, which facilitatesthe welding with the phase.

In addition, preferentially, according to a first variant or thisembodiment, the electronic module 10 is a control module 30 that alsocomprises, as illustrated in FIGS. 2A and 2B:

a third series of signal tongues 106 c that are aligned on the externalperiphery of the triangular housing of the module, the peripherycoinciding with the outside diameter of the machine. This series oftongues makes it possible to be connected to a signal connectorintegrated in a cover, and

a second series of signal tongues 106 b that are aligned parallel to thethird series of signal tongues 106 c and offset towards the inside ofthe module. This second series of tongues conveys complementary signalsthat have not been able to be integrated in the first series of signaltongues 106 a, for example signals SC for a control element of a switch.This enables the two series of signal tongues 106 b and 106 c to becropped on a single occasion. It should be noted that the third seriesof signal tongues 106 c is preferentially positioned higher than thesecond series of signal tongues 106 b in order to facilitate the weldingof a cover to the control module after having carried out the welding ofa signal interconnection piece.

In other words, the second and third series of signal tongues 106 b, 106c are aligned on the same face on which the ends of the powerconnections are disposed:

a housing 112 for stator position sensors.

It should be noted that the interconnections between the transistors andthe associated tracks are effected by “wire bounding” hard-wiredconnections as illustrated in FIG. 2C. In the context of a module with asingle transistor per potential, there is one transistor disposed on theelectrical conductor 103, which is connected to the phase track 105 andto the ceramic 1110 of the control element 111, while a secondtransistor is disposed on the phase track 105 and is connected to thenegative electrical conductor 104 and also to the ceramic 1110. Itshould be noted that it would also be possible to have a transistor onthe negative electrical conductor 104.

It should be noted that, in this example, there are four transistors,two transistors for the “low side”, indicated LS, and “high side”,indicated HS, of an arm, that is to say two transistors per potential inorder to increase the power of the machine.

In addition, preferentially, according to a second variant of thisembodiment, the electronic module 10 is an excitation module 40, asillustrated in FIG. 2D. It comprises electronic components 102, inparticular MOS transistors and diodes, which represent the excitationstage of the rotor of the machine.

Thus the electronic modules 10 have, with regard to the arrangement ofthe electrical conductors 103, 104 and their ends forming electricalconductors inside each module and with regard to the arrangement of thesignal connection element 106, a standardized architecture makes itpossible to use the modules on different types of electrical machine.This standardization of the architecture makes it possible to replaceany electronic module 10 with a module with the same architecture. Inaddition, this makes it possible to integrate the modules directly onthe rear bearing of the machine. In this way the power and controlelectronics are integrated on the machine directly. The electronics areno longer in an electronic power card in a separate housing.

Thus, according to the architecture of an electronic module 10 describedpreviously, it is possible to have power modules 20 (FIGS. 1A to 1C), acontrol module 30 (FIGS. 2A to 2C) and an excitation module 40 (FIG.2D).

In the case of the power modules 20, the electronic components 102,illustrated in FIG. 1C, comprise for example:

-   -   a set of electronic switches 110 intended to produce a rectifier        bridge/inverter arm for a phase of the machine;    -   control elements 111, called drivers, associated with the        switches; and    -   a temperature sensor 118 (positioned on a ceramic) for the phase        track 105.

The electronic switches 110 can for example be MOSFET-technologytransistors that are in the form of packaged components, that is to saypresented with a can, or, in order to increase the compactness of thearrangement of the modules and to reduce costs, in the form of barechips, that is to say without a can. The electronic switches (MOSFETs)110 are controlled by the control elements 111, normally called drivers,on a ceramic 1110 with additional components. Preferentially, thedrivers are ASICs. The electronic elements can also be diodes of an armof a bridge rectifier, since MOSs have a better efficiency than diodes.The number of electronic components depends essentially on theconstraints of the particular application (three-phase or hexaphasemachine for example), the level of power required by the machine, etc.

For a three-phase machine, there will preferably be three power modulesserving to produce an inverter (one module per phase). More generally,the machine is a polyphase machine (x phases), preferably having onemodule per phase.

FIG. 1D illustrates the hard-wired connections, normally referred to as“wire bounding”, between the transistors and the electrical conductor104 and the phase track 105. It should be noted that, in this example,there exist four MOS transistors, so as to increase the power of themachine. Naturally there may be only two of them. It should be notedthat the ceramic 1110 also serves as a support for electronic componentsbut also as interconnection between the transistors and the controlelement 111.

The control module 30 makes it possible to control the machine and inparticular the adjustment of the excitation current by controlling thedrivers of the MOS transistors. It also has, as illustrated in FIG. 2A,an electronic control component 102CTRL, capacitors 102CA and atransformer 102TR for supplying the control element 111 of the powermodules. Control signals will thus be sent from the control component102CTRL to the control element 111 of the power modules.

The excitation module 40 makes it possible to supply the coil of therotor of the machine, the module comprising in a conventional manner MOStransistors and diodes for determining the current in the rotor.

Thus the control module 30 and the excitation module 40 repeat thearchitecture of the electronic module 10 and in particular thearrangement of the ends of the electrical conductors 103, 104 and thesignal connection element 106.

According to a variant embodiment, the control module 30 and theexcitation module 40 can be replaced by a common excitation and controlmodule.

All the modules 20, 30 and 40 are mounted on a rear bearing of therotary electrical machine.

In a second non-limitative embodiment, illustrated in FIG. 3A, theelectronic module 10 differs from the first embodiment in that:

-   -   in place of the fixing means 108, it has support zones 114 for        receiving stays belonging to a signal interconnection piece, as        will be described below, which makes it possible to omit the        fixing studs 113 so that the cost of the parts and assembly are        reduced, and this makes it possible to obtain a simpler        assembly.

The electronic module 10 can be seen in view from below in FIG. 3B andin a view without overmolding in FIG. 3C for a power module. It shouldsimply be noted in FIG. 3B that the module preferably comprises a fixingclip 125 for a plastic cover for a module in order to protect theprotective gel for the components. This fixing clip can be replaced by abonding of the cover or ultrasonic welding for example.

FIG. 3D presents a variant embodiment for a control/excitation module30/40. It should be noted that having a single module for the controland excitation function makes it possible to save in terms of size.

FIG. 3E presents the “wire bounding” hard-wired connections of thisvariant. It should be noted that there exists an interconnection betweenthe control ceramic and the excitation ceramic (substrate) produced by a“wire bounding” hard-wired connection to allow transmission of signalsbetween the excitation part and the control part.

In the first two embodiments described, preferentially, the ends of theelectrical conductors 103, 104 are flat and flush on the bottom face ofthe module. Thus this configuration has the advantage of being able toweld tracks of a power plate (described in detail below) on the ends oftracks of a module by transparency (flat on flat).

In a third non-limitative embodiment, illustrated in FIG. 4A theelectronic module 10 is configured so as to be fixed to a dissipator,itself fixed to the rear bearing of the machine.

It differs from the second embodiment in that:

-   -   the end 105 z of the phase track 105 is perpendicular to the        bottom face of the module and projects beyond the housing 101 of        the module and its plastic cover, and extends upwards. Thus this        allows axial welding and thus prevents being interfered with by        the lugs fixing the alternator starter on the engine, whatever        the engine of a manufacturer; and this facilitates access to the        welding tool;    -   the end of the electrical conductor 103 (B+) is a folded tongue        allowing radial laser welding with a power plate or axial        electric welding by electrodes; it extends axially upwards with        respect to the housing 101 of the module and projects beyond the        housing in order to engage the electrodes, i.e. it is        perpendicular to the bottom face of the module; the tongue        projects beyond the dissipator. This makes it possible to        connect a power interconnection piece 21 with the module from        below;    -   the end of the negative electrical conductor 104 (B−) is no        longer a tongue but a hollow cylindrical metal insert allowing        electrical connection to a dissipator 80 via the track B−and a        screw 1150 corresponding to the orifice 115, the screw making it        possible to compress the track on the insert and thus to        compress the track plus insert on the dissipator so as to effect        the earthing of the module, the dissipator being earthed as will        be described in detail below;    -   the positioning pins or recesses 109 situated on the bottom face        are positioned differently. A first positioning bin 109 a is        positioned as close as possible to the signal connection        elements 106, and preferentially centered on the middle one, in        order to reduce the positioning tolerance of the tongues with        respect to any clearance that may exist between the second        positioning pin 109 b and the corresponding orifice 609 b        (described in more detail below) of the dissipator bearing. In        this way the positioning errors of the tongues with respect to        the dissipator are reduced. As illustrated in FIG. 4B, this        first positioning pin 109 a is situated at the middle of the two        signal tongues 106 a. It should be noted that the first        positioning pin 109 a serves to position the module along the        axis X-Y, and the second positioning pin 109 b serves to orient        the module in terms of rotation and is the furthest away from        the signal tongues 106 a; and    -   one of the protective pins or guides 107 is placed more towards        the outside of the module so that there exists a kind of support        119 to make it possible to receive a stay of a signal plate. The        pins or guides 107 prevent the signal connection elements 106        bending between the time of the manufacture of the module and        its assembly on the machine, and serve as preliminary guidance        for a signal interconnection piece (described below).

In addition, the electronic module 10 according to this third embodimentalso comprises:

-   -   an insert 120 comprising a fixing orifice 115, the insert        allowing earthing of the module, and the orifice being intended        to fix the module to a dissipator by means of screws 1150 for        example; and    -   means 126 of electrical protection of the end of the electrical        conductor 103 (B+) that prevent a short-circuit between the        potentials B+(power track of the power interconnection piece)        and B−(dissipator mass).

A view without overmolding of a power module 20 according to this thirdembodiment is shown in FIG. 4C.

A view with the “wire bounding” hard-wired connections is shown in FIG.4E.

Preferentially, each power module 20 comprises a plate 1022 of lowresistance and low thermal conductivity, preferentially made fromaluminum (the same resistance as the dissipator) or copper.

Thus there are:

-   -   the electronic components 102 welded to the metal tracks;    -   the metal tracks, which are visible on the bottom face of the        housing of the module, are bonded to the plate 1022 by an        electrically insulating and thermally conductive adhesive, for        example a glass-ball adhesive, the adhesive electrically        insulating the tracks from each other and the tracks with        respect to the outside; and    -   the plate 1022, which is placed on the dissipator.

The plate 1022 is illustrated in FIG. 4D (representation incross-section along an axis A-A in FIG. 4C). It should be noted thatthis plate can be used in the same way on the other control orexcitation modules in the context of visible tracks.

The plate thus makes it possible to test the electrical insulation ofeach module independently before assembly on the dissipator ordissipator bearing. Thus, if there exists a problem of short-circuit dueto faulty application of the insulating adhesive, this plate 1022 avoidsthe scrapping of all the modules mounted on the dissipator. Only themodule posing a problem will be disposed of before it is assembled onthe dissipator.

According to a variant of this third embodiment, the electronic module10 comprises, as illustrated in FIG. 5A:

-   -   a signal connector 116;    -   a screw 117 a affording electrical contact between two tracks        117 b (+EX, −EX) of a brush holder 50 and the electronic module        10; and    -   a screw 117 c for mechanical holding on the dissipator and        making it possible to withstand the mechanical forces of the        signal connector 116.

More particularly it is the control module 30 or the control/excitationmodule that comprises the signal connector 116 and the screw 117 a. Itshould be noted that the brush holder is here in a single piece with thecontrol module 30. Indeed it is molded on with the module.

The presence of the signal connector 116 has the advantage of:

-   -   eliminating welds making it possible to effect electrical        connections between the cover and the modules, compared with the        first embodiment;    -   avoiding problems of welding and impermeability; and    -   saving time in the manufacturing process.

There therefore no longer exist any external signal tongues 106 c as inthe first or second embodiments, which makes it possible to reduce thematerial of the tracks (those in the cover) as will be seensubsequently.

FIG. 5B is a view from below of the control module 30 according to thisthird embodiment.

As can be seen, the first positioning pin 109 a is as close as possibleto the two series of signal tongues 106 a and 106 b in order to limitany errors in positioning of the tongues with respect to the dissipator.

In addition there can also be seen:

-   -   a metal plate 121 fixed by the screw 1150, the plate        preferentially being made from aluminum and thus being connected        to the dissipator mass via the screw 1150, the plate comprising        substrates 123 of the ceramic type, on which electronic        components are integrated; and    -   position sensors 122 for giving the position of the stator of        the electrical machine.

FIG. 5C is a view from above of the control/excitation module withoutovermolding, without the signal connector 116 and without the brushholder 50. FIG. 5D shows the view from below.

FIG. 5E is a first view without pre-molding and without overmolding ofthe tracks of the control/excitation module in which there can inparticular be seen:

-   -   substrates 123 comprising the electronic components for        controlling the machine; and    -   an excitation part 124 comprising the electronic components for        excitation of the machine via the brush holder 50.

The tracks of the module can also be seen in the following FIG. 5Fwithout pre-molding and without the plastic overmoldiing in a view frombelow.

It should be noted that the pre-molding is an operation that takes placebefore the overmolding and that makes it possible to hold certainelements in position, such as the signal connection element 106 forexample.

It should be noted that, in all the embodiments, the electroniccomponents 102, in particular the MOS transistors, are mounted on thepower connections, namely here the positive electrical conductor 103 andthe phase track 105.

Preferentially, in all the embodiments presented above, the power tracksof the modules are visible on the bottom face of the modules. It is thuspossible to isolate them electrically from the dissipator or dissipatorbearing by means of adhesive in place of the plastic of the housing 101.The use of adhesive in place of the plastic of the housing 101 makes itpossible to have a lesser thickness under the modules (approximately 0.2mm in a non-limitative example) and to have a lower thermal resistancethan plastic so as to have better dissipation in the dissipator bearingor dissipator.

It should be noted that, in all the embodiments presented above, it isof course possible to include or not the signal connector 116 in thecontrol module or control/excitation module if so desired. If it is notincluded, it will be in the cover.

It should be noted that the electronic module according to all theembodiments presented above has the following additional advantages:

-   -   it uses bare chips for the electronic components instead of        so-called packaged standard components, so as to reduce the        size;    -   it includes the elements for controlling the MOS transistors,        referred to as drivers;    -   a module is configured in order to be perfectly integrated on        the dissipator or dissipator bearing so that:        -   it does not block the axis of the bearing in which the shaft            of the rotor is introduced;        -   there exists an axial cooling with the attached dissipator            (not integrated);        -   all the ends of the power and signal tracks are outside the            circumference of the dissipator or dissipator bearing, which            facilitates the connections to be established, unlike the            case where they are inside the circumference, so as to be            accessible and so that there exists more space available on            the outside diameter than inside for the ends;    -   a module is preferentially configured for a single phase so        that:        -   the hook of the module is opposite the natural exit of a            stator phase;        -   there is one module per phase. Thus adaptation to the space            available on the dissipator or dissipator bearing is easier            compared with a single module comprising three phase tracks,            and this in an optimum manner;    -   the definition of the module makes it possible to have a power,        control and excitation module with the same architecture; and    -   in the event of failure of welding of one of the transistors, it        avoids too much scrap compared with a single module for the        three phases of the stator.

It should be noted that it is also possible to provide a singleovermolding for all the power modules 20, the control module 30 and theexcitation module 40 or control/excitation module 30/40.

At this moment there would be a single module that would comprise thepower, the control and the excitation, the module then comprising threephase tracks.

An electronic module 10 cooperates with the following elements:

-   -   a dissipator bearing 60 (dissipator integrated in the bearing,        i.e. in a single piece with the bearing), or a dissipator 80        (dissipator not integrated in the bearing, i.e. attached to the        bearing);    -   a signal interconnection piece 22;    -   a power interconnection piece 21; and    -   a cover 70.

These elements are described below.

Dissipator Bearing

The function of a dissipator bearing is to discharge the heat from theelectronic modules.

The rear dissipator bearing 60, shown in FIG. 6, comprises, according toa first non-limitative embodiment:

-   -   a plurality of positioning orifices 609, preferentially two        orifices 609 a, 609 b per module, in order to position the        modules on the bearing, the orifices being situated on the same        diameter, i.e. in the example illustrated ten orifices;    -   a plurality of fixing orifices 608 for receiving the three        fixing studs of each module on which the power plate will be        positioned, that is to say in the example illustrated fifteen        orifices;    -   air inlets 601 comprising fins 606;    -   air outlets 602 comprising fins 606;    -   various recesses referenced 603 for the rotor shaft of the        rotary electrical machine, 604 for the Hall effect sensors        making it possible to know the rotor position, and 605 for a        brush holder 50; and    -   positioning orifices 610 for positioning a signal plate, here        two positioning orifices 610 a and 610 b that are distributed on        each side of the diameter of the dissipator bearing.        Preferentially one of the orifices is the reference control for        the dissipator bearing, and thus an already existing orifice is        used.

It should be noted that FIG. 6 shows the locations of the variousmodules. Thus the locations marked P, C and E receive respectively thethree power modules 20, the control module 30 and finally the excitationmodule 40.

According to a second non-limitative preferential embodiment illustratedin FIG. 7, the dissipator bearing 60 comprises:

-   -   a plurality of fixing orifices, here four, 681, 682, 683 and 684        for receiving four studs holding the signal plate;    -   a fixing orifice 685 for receiving a fixing screw of a brush        holder 50, there is no stud, which avoids reducing the        cross-section of the track B+of a power plate;    -   the following same elements as the first embodiment:        -   air inlets 601 comprising fins 66;        -   air outlets 602 comprising fins 606;        -   various recesses 603, 604 and 605; and        -   the positioning orifices 610 a and 610 b for the signal            plate.

It will be noted that the control and excitation functions have beencombined in a single control/excitation module. Moreover, the locationC/E and P respectively of the control/excitation module and the powermodule 20 in FIG. 7 will be noted.

The function of the dissipator 80 is to discharge the heat from theelectronic modules.

The dissipator 80 as illustrated in plan view in FIG. 8A is independentof the rear bearing of the rotary machine.

The dissipator 80 as illustrated in plan view in FIG. 8 a is independentof the rear bearing of the rotary machine.

It comprises, according to a non-limitative preferential embodiment:

-   -   a base plate 801 preferentially made from cast aluminum; and    -   fixing orifices 806 on the rear bearing of the machine, here        four, in order to receive fixing studs of a signal plate;    -   an electrical connection orifice 805 for connecting the        dissipator to earth via the power interconnection plate by means        of a nut;    -   fixing orifices 804 for fixing the modules, here four, and        connecting them to the dissipator earth via an insert;    -   a fixing orifice 807 for fixing a signal connector of the        control/excitation module via an insert;    -   mechanical positioning orifices 808 for positioning a power        interconnection piece 21, here two distributed on each side of        the diameter of the dissipator;    -   recesses 809 on the circumference for receiving electrical        protection means, here three, for the positive track (B+) of the        power interconnection piece;    -   positioning orifices 810 for the modules, here two per module,        that is to say eight orifices;    -   mechanical positioning orifices 811 for positioning a signal        interconnection piece 22, here two distributed on each side of        the diameter of the dissipator; and    -   recesses 812 for inserting phase housings of a power plate as        will be seen in detail below. There therefore exist three of        them here,    -   recesses 815, 816, 817 for receiving respectively a brush        holder, position sensors and the rotor shaft.

The locations C/E and P respectively of the control/excitation moduleand the power modules 20 will be noted.

FIG. 8B shows a plan view of the dissipator.

It can be seen that the dissipator also comprises:

-   -   blocks of cooling fins 802 intended to substantially increase        the heat dissipation of the power modules 20, the blocks being        situated on the bottom face in the position of use of the base        plate 801;    -   support zones 814 for receiving force stays for the power        interconnection piece that make it possible to withstand the        engine vibrations; and    -   a protrusion 813 that guides the air from the radial inlet of        the machine towards the inside of the machine and thus prevents        the air stagnating at the dissipator. This is also the case for        the axial air. It is guided towards the inside of the machine.        It should be noted that the fins at this level pass through the        protrusion 813. A section X-X of the protrusion can be seen in        FIG. 8C.

In addition, it should be noted that the base plate 801 is configuredfirstly so as to be able to be assembled in a sandwich between a powerinterconnection plate and the modules, and a signal interconnectionplate, and secondly to leave at the center a sufficiently large passagefor the cooling air of the electrical machine.

As indicated in FIG. 8D, a first flow of the air will enter the machinein this way axially FA. This has the advantage of increasing the speedof the air and thus reducing the pressure drops compared with a radialflow (the case of the first and second embodiments of the dissipatorbearing described previously).

In this way, a looping of air heated by the machine between an outputand an input of the dissipator bearing is avoided (for the air incomingaxially) and thus re-injecting hot air into the machine is avoided.

More particularly, it is the recess 817 that is configured so as toallow air to pass around the rotor shaft and is therefore wider than thediameter of the rotor shaft or, to be more precise, of the shaftcollector protector.

In this way the standard cooling applied to a conventional alternator isapproached.

Moreover, the axial air flow is guided by the first slope 813P1 of theprotrusion 813 of the dissipator so that there is no stagnant air on thebottom face of the dissipator level with the fins.

In addition, by virtue of the positioning of the dissipator 80described, there is also a second air flow that is radial between thedissipator 80 and the power interconnection piece 21. This can also beseen in FIG. 8D. This radial air FR enters through the dissipator andleaves again through the fins 606 in the bearing. This radial air flowincreases the output of air and therefore improves the cooling of themachine, the latter thus being more efficient than if there were only anaxial air flow.

In addition, by virtue of the protrusion 813 situated level with thefins, this radial air flow does not stagnate since it is guided by thesecond slope 813P2 of the protrusion 813 towards the inside of themachine.

It should be noted that these radial FR and axial FA air flows areaccelerated by the fan of the machine, which gives rise to a bettercooling of the machine plus the electronics because in particular of thearrangement of the dissipator as described above.

Signal Interconnection Plate

The signal interconnection piece 22 is intended to convey varioussignals necessary for the functioning of the modules and, thereby, forthe correct functioning of the rotary electrical machine. Such signalsare for example:

-   -   a signal for the operating mode of the electrical machine, for        example motor or generator;    -   a signal indicating the temperature of the modules;    -   a signal sending back a fault detected on the modules;    -   a control signal for the switches of the MOSs etc.

These signals are conveyed between the power modules 20 and the controlmodule 30.

FIGS. 9A to 9C show a first non-limitative embodiment of the signalinterconnection piece 22.

It comprises:

-   -   a base plate 220 made from insulating material, preferentially        made from plastic, and preferentially substantially cylindrical,        which moulds on metal signal tracks TS;    -   a central recess 223 for lightening the plate in terms of        material;    -   recesses 221 a for leaving visible metal tracks TS, the tracks        comprising interconnection orifices 2210, here five orifices,        the axes of which are disposed in a plane P2 (shown in FIG. 9C)        perpendicular to the surface of the plate and passing        substantially through the rotor rotation axis AX, the orifices        being intended to receive the signal connection element 106 of        an electronic module with a view to being connected        electrically;    -   a connection recess 221 b for leaving visible metal tracks TS,        the tracks comprising interconnection orifices 2211, disposed at        the external periphery of the signal interconnection piece 22,        the orifices being intended to receive the signal connection        element 106 of a control module, here three orifices; and    -   fixing lugs 222 intended to be inserted in one of the three        holding studs 113 of an electronic module, and intended to        receive a fixing nut, the fixing lugs holding the signal        interconnection piece 22 on the modules, by means of the studs,        first lugs 222 a being disposed on the outside diameter of the        plate and projecting beyond the plate, and second lugs 222 b        being disposed on the internal diameter of the plate and also        attenuating vibrations of the plate.

It should be noted that the recesses 221 a and 221 b can be protectedsubsequently against the external environment by a resin for example.

It should also be noted that the base plate 220 comprises orifices 2210z, 2211 z opposite the orifices of the metal tracks TS, as illustratedin FIG. 9B.

The signal interconnection piece 22 also comprises:

-   -   positioning pins or studs 224 for assembly on a dissipator        bearing 60, here two as illustrated on the view from below in        FIG. 9B; and    -   metal signal tracks TS configured to adapt to the shape of the        plate and to the position of the signal connection element 106        of the modules, and comprising interconnection orifices 2210,        2211 as illustrated in FIG. 9C. The tracks are preferentially in        the same plane. Moreover, they are preferentially configured in        the form of arcs of a circle essentially concentric with respect        to the rotor rotation axis.

FIGS. 10A to 10C depict a second preferential embodiment of the signalinterconnection piece 22.

This signal interconnection piece 22 comprises:

-   -   in place of the fixing lugs of the first mode, stays 225 for        pressing the modules against a dissipator bearing, first stays        225 a and second stays 225 b being positioned respectively on        the external or internal periphery of the plate, here nine in        total; there are thus three support points on each module;    -   in place of the three recesses per module, only three support        inserts 226 intended to receive three studs 226 g, for fixing to        the dissipator bearing 60; and    -   a metal insert 226 for receiving a screw 226 v for fixing the        plate to the dissipator bearing. This screw avoids reducing the        cross-section of the positive power tracks (B+) of the power        interconnection piece 21 (described below).

These four inserts also prevent flow of the overmolding plastic. It willtherefore also be possible to use them for the first embodiment.

The signal interconnection piece 22 also comprises:

-   -   at least one fixing housing or holding clip 227 for fixing the        power interconnection piece 21 and receiving a fixing clip or        lug (218), here two housings; and    -   an additional central recess 228 for receiving a brush holder.

In a first variant embodiment of this mode, the plate also comprisesseparators 229 for signal connection element 106 so as to preventshort-circuits between the tongues, short-circuits due in particular tosalt spray. In this way the length of the electrical path between thetongues is increased.

In another variant, the plate does not have any separators. At thismoment, in order to isolate the tongues from each other, seals areprovides that surround the signal connection element 106 on the modulesthemselves. Subsequently the signal interconnection piece 22 willcompress these seals.

It should be noted that these two variants apply to the two embodimentsof the electronic module described above and to the third embodiment,which will be described later.

In FIG. 10C, it is possible to see the concentric metal tracks of thesignal interconnection piece 22. The metal tracks are configured toadapt to the position of the signal connection element 106 of themodules, and preferentially to the shape of the plate, and in additionto pass round the four inserts 226. They are preferentially configuredin the form of arcs of a circle essentially concentric with respect tothe rotor rotation axis.

It should be noted that the stays 225 are, non-limitatively, cylindricalin shape. This shape has a sharp edge 2250.

In addition, it should be noted that the signal interconnection piece 22according to this second embodiment has the following same elements asthe plate according to the first mode:

-   -   the base plate 220;    -   the recesses 221 a and 221 b;    -   the central recess 223 intended to receive here a rotor shaft;    -   the positioning pins 224; and    -   the metal tracks TS with the orifices 2210 and 2211.

It should be noted that, for the first and second embodiments describedabove, the signal tracks are preferentially configured inside thediameter on which the power terminals (described in detail below) areproduced. This enables the power interconnection pieces 21 (describedbelow) to fit on top of the signal interconnection piece 22. Thusassembly is facilitated and the signal tracks do not interfere with thepower tracks.

FIGS. 11A to 11D depict a third non-limitative embodiment of the signalinterconnection piece 22.

It differs from the second embodiment in that:

-   -   it no longer has any holding clips 227 for positioning the power        interconnection piece 21 since in this embodiment the power        interconnection piece 21 is situated below the signal        interconnection piece 22, as will be seen in detail below; and    -   the stays 225 a and 225 b have a different shape. They have a        shape that no longer comprises any sharp edge, which prevents        the stresses undergone by the plastic being concentrated on the        sharp edges. In this way the risk of breaking the stays is        reduced.

The signal plate 32 also comprises:

-   -   hollowed-out protuberances 230 for pre-positioning the plate on        the modules. Here there exist two protuberances. They serve in        particular for pre-guidance during the process assembly. This        thus makes it possible to subsequently fix the positioning pins        224 of the signal interconnection piece 22 in the dissipator 80.        It will thus be possible to position the signal interconnection        piece 22 before the assembly of the signal connection element        106; and    -   housings 231 for housing therein filtering capacitors. These        capacitors will be connected to the electronic modules. The        housings afford good mechanical strength for the capacitors.        Resin will be deposited in the housings.

Moreover, it should be noted that the signal interconnection piece 22according to this third embodiment has the following same elements asthe plate according to the second embodiment:

-   -   the base plate 220;    -   the recesses 221a and 221 b;    -   the central recess 223;    -   the additional central recess 228 for the brush holder;    -   the four inserts 226;    -   the positioning pins 224; and    -   the metal tracks TS with the orifices 2210 and 2211.

According to a first variant of this embodiment, the orifices 2210 and2211 are configured so as to effect a tin weld between the orifices andthe corresponding signal connection element 106. These are thereforeholes with a bevel as illustrated in FIG. 11A and in FIG. 11B in viewfrom below.

According to a second variant of this embodiment, the orifices 2210 and2211 are configured so as to effect a laser weld between the orificesand the corresponding signal connection element 106. These are thereforefolded micro-tongues as illustrated in FIG. 11C.

In FIG. 11D, the metal tracks of the signal interconnection piece 22 canbe seen. The metal tracks are configured so as to adapt to the positionof the signal connection element 106 of the modules, and preferentiallyto the shape of the plate, and in addition to pass round the fourinserts 226. They are preferentially configured in the form of arcs of acircle essentially concentric with respect to the rotor rotation axis.

Thus, unlike an electronic card for fulfilling the signal function, sucha signal plate has the advantages of:

-   -   withstanding high temperatures, for example 260° C., unlike a        conventional PCB electronic card, such a PCB card being composed        of copper tracks with a polymer insulator, the copper tracks not        withstanding high temperatures;    -   being able to be centered above the electronic modules 10;    -   comprising metal tracks not necessarily made from copper. This        is because, having regard to the relatively low power conveyed        by these tracks, a material with a low electrical resistance is        not necessarily required. Thus the tracks can for example,        non-limitatively, be made from steel;    -   be as close as possible to the modules, which avoids having        signal tongues for the excessively long modules and thus        avoiding problems of plugging in; and    -   by virtue of the metal tracks, which do not overlap, a track        cutting is achieved in one go, a fine thickness of the plate is        obtained, and therefore a saving in axial size of the whole of        the machine, and a facilitated manufacture of the signal        interconnection plate.

It should be noted that, naturally, in all the embodiments presentedabove, it is also possible to provide, instead of the interconnectionorifices 2210, 2211, other interconnection means such as folded tonguesfor example.

Power Interconnection Plate

The power interconnection piece 21 makes it possible to distribute thepower between the modules 20, 30, 40 from outside (in particular thevehicle battery).

This piece is independent of the electronic modules, which makes itpossible to supply each module with current independently and thus avoidthe heating of the modules relating to the passage of the currentintended for one module in all the modules. Thus, according to theconfiguration of this piece and the associated modules, there is no flowof current between the three power modules.

The power interconnection piece 21 is, in the most simple case, in theform of a plate produced from an electrically insulating material,preferably plastic.

In a first non-limitative embodiment, illustrated in FIGS. 12A to 12C,it comprises:

-   -   a central recess 210 for lightening the plate in terms of        material;    -   power interconnection tracks 211 (−BATT), 212 (+BATT);    -   negative 2110 and positive 2120 power terminals issuing from the        respective power interconnection tracks 211, 212;    -   a plastic overmolding 213 on the power interconnection tracks        211 and 212;    -   a first recess 214 a;    -   a second recess 214 b; and    -   fixing lugs 215.

The elements of the power interconnection plate are described in detailbelow.

The power interconnection tracks 211, 212 are disposed at least on oneface of the plate. These are tracks made from a metal with lowresistance, preferably copper, which are overmolded in the plasticsmaterial of the power interconnection piece 21.

They can be produced in the form of a flat strips clipped, riveted,adhesively bonded or fixed in any other suitable manner to the plasticplate.

According to a preferential embodiment, the power interconnection tracks211, 212 are interleaved (the power interconnection track 211 issurrounded by the power interconnection track 212) and concentric and onthe same plane. In this case, the negative power terminals 2110 arefolded so as not to interfere with the positive power interconnectiontrack 212 (+BATT). In this way, it is possible to optimize the locationof the recesses 214 a, 214 b in order to orient a cover according to therequirements of a customer connector making the connection of themachine with the outside. The power interconnection tracks 211 and 212are not superimposed so as to allow electrical connection with thetracks of such a cover, the zone comprising the recesses 214 a and 214b.

According to a second embodiment, the power interconnection tracks 211,212 can be superimposed on one another. This is beneficial to the radialsize.

Finally, it should be noted that each of the power interconnectiontracks 211, 212 comprises a hole 217 a, 217 b making it possible toposition the track in terms of x, y in a mould, the latter making itpossible to carry out the plastic overmolding 213.

The power interconnection tracks 211, 212 have respectively negativepower terminals 2110 (−BATT) in an L shape, and positive terminals 2120(+BATT). The terminals extend radially towards the external periphery ofthe power interconnection piece 21. These terminals have curved freeends. The precise dimensions and position of the terminals 2110, 2120are determined so as to enable them to be positioned above the ends ofthe electrical conductors 104, 103 of each of the modules in order to beable to be connected to the tracks by means of welding, brazing orweld-brazing for example. This configuration of the power terminals (inan L shape and having ends curved by bending) on the outside diameterthus facilitates the assembly with the modules. These terminals thusmake it possible to obtain an electrical connection with thecorresponding electrical conductors 103, 104 of the electronic modules10 so that the electrical power is distributed in each of the modules.It will be noted that the positive power interconnection track 212overlaps the negative power terminals 2110.

The overmolding 213 comprises a first recess 214 a for an electricalconnection of the power interconnection track 211, preferably by laserwelding, with a cover to the battery, and a second recess 214 b in theovermolding for an electrical connection of the power interconnectiontrack 212, preferably by laser welding, with a cover to the battery.

Moreover, the overmolding 213 comprises assembly recesses 216 enablingan assembly tool to pass through the plate and assemble the reardissipator bearing with a front bearing.

It should be noted that the ends of the power terminals 2110 and 2120are not overmolded so that the ends can bear on the ends of theelectrical conductors 104, 103 of the modules. Preferentially, the wholeof the power terminal piece is not overmolded so that assembly on theends of the tracks is facilitated. This is because this affords morebending in such an assembly.

The lugs 215 extend substantially radially over the external peripheryof the interconnection plate. Each of the lugs 215 is provided with anorifice making it possible to pass therein, when the various modules andthe other elements of the arrangement are assembled, fixing means suchas threaded rods or bolts or studs or any other suitable fixing element.

In a second non-limitative embodiment, illustrated in FIGS. 13A to 13C,the power interconnection piece 21 comprises:

-   -   a supplementary central recess 2101;    -   at least one fixing clip or lug 218;    -   inserts 219 a, 219 b for receiving holding studs;    -   a mechanical stop 2112;    -   at least one support pin 2113; and    -   an orifice 219 c.

The elements of the power interconnection plate are described in detailbelow.

The supplementary central recess 2101 allows the insertion of the brushholder with its protector. In this case, the brush cage protector is anindependent piece assembled on the brush holder, and the brush holdermay be removable with respect to the control/excitation module, whichfacilitates maintenance of the machine in particular in a replacementcontext, that is to say when the brushes (and therefore the brushholder) are changed when they are worn. Thus, instead of changing allthe electronics (the modules and the two plates), only the brush holderwill be changed (if the electronics are not faulty).

The fixing clips or lugs 218 enable the power interconnection piece 21to be held mechanically on the signal interconnection piece 22, herethree.

The inserts 219 a and 219 b for receiving the holding studs, here two intotal, and for connecting the power interconnection tracks 211, 212 to acover 70. The two inserts 219 a, 219 b make it possible to gain accessto the power tracks so that an overmolding 213 can be effected on thetracks as illustrated in FIG. 13A. These two inserts thus allowmechanical holding of the plate 1 and an electrical connection.

The last orifice 219 c permits solely mechanical holding of the powerinterconnection piece 21 by means of a stud.

The mechanical stop 2112 makes it possible to stop the powerinterconnection piece 21 in translation when it is assembled. It bears,for example, on the control/excitation module. In addition this stop hasa shorter length than the power terminals 2110 and 2120 of the powertracks so that the terminals bear on the tracks of the correspondingmodules before the stop bears on the control module. The stop isdisposed on the outside diameter of the plate and projects beyond thisplate.

The at least one support pin 2113, here two, enable the powerinterconnection piece 21 to bear on the dissipator bearing duringassembly.

The power interconnection piece 21 comprises, as described in the firstembodiment:

-   -   the central recess 210;    -   the power interconnection tracks 211, 212;    -   the negative 2110 and positive 2120 power terminals; and    -   the overmolding 213.

It should be noted that the overmolding 213 comprises here a recess 2130for lightening the plastics material, the recess being possible since nofacing power tracks exist. In the same way as in the first embodiment,the power terminals 2110 and 2120 are not overmolded.

The power interconnection tracks 211 and 212 are shown in FIG. 13C.

In addition, according to the first and second embodiments:

-   -   the power interconnection piece 21 can also integrate passive        filtering components 2114 shown in FIG. 13B, for example        capacitors connected between the power interconnection tracks        211 (−-BATT), 212 (+BATT) via micro-tongues 21140 a and 21140 b.        This makes it possible for example to filter the voltage of the        on-board system of the motor vehicle and to filter in particular        the oscillations due to the electrical conversion components,        MOSs, diodes, etc.;    -   preferentially, the ends of the power tracks are flat and flush        on the surface of the module. Thus the advantage of this        configuration is being able to weld tracks on a power plate        (described in detail below) to the ends of the tracks of a        module by flat-on-flat transparency;    -   the power interconnection piece 21 can also integrate a brush        cage protector (not shown) that makes the brush holder        impervious. This gives one part less to assemble. The brush        holder allows the supply of the excitation current issuing from        the excitation module to the rotor via brushes. The protector        then comprises positioning guides that will make it possible to        position the protector opposite the brush holder;    -   preferentially, the positive terminals 2120 are rigid lugs        defining a reference support plane for the power piece on the        corresponding tracks of the modules; and    -   preferentially, the negative power terminals 2110 are flexible        lugs for taking into account the assembly tolerances. Thus, when        the modules and the plate are assembled, this will make it        possible to deform the tracks of the power plate before welding        by transparency. This thus facilitates putting the power        interconnection tracks in contact with the corresponding tracks        of the modules. It will be possible to use this flexibility also        for the first embodiment, also for the third embodiment        described below (although this is not necessary).

FIGS. 14A to 14E show a third non-limitative embodiment of the powerinterconnection piece 21.

The power interconnection piece 21 comprises:

-   -   inserts 210 d for establishing a mechanical connection with the        rear bearing of the machine;    -   stator phase protection means 211 d;    -   means 212 d of positioning on the rear bearing of the machine;    -   force stays 213 d;    -   means 214 d of positioning the plate in the dissipator 80;    -   a fixing terminal 215 d for fixing the plate to the dissipator        80;    -   an electrical insert 216 d;    -   a power connector 219 d;    -   positive 221 d (B+) and negative 222 d (B−) tracks molded on in        plastic;    -   positive power terminals 217 d issuing from the positive track        B+;    -   means 218 d of protecting the positive power terminals 217 d;    -   a terminal 220 d for mechanical connection to a client power        connector (not shown) connected to the battery; and    -   a mechanical connection orifice 220 e connected to the        connection terminal 220 d.

The elements of the power interconnection plate are described in detailbelow.

The inserts 210 d for establishing a mechanical connection with the rearbearing of the machine, by means of screws for example, here four intotal:

the stator phase protection means 211 d are situated on the outsidediameter of the plate and project beyond the plane of the plate, themeans preventing contact between a stator phase and the dissipator massor bearing mass in particular;

the means 212 d of positioning on the rear bearing of the machine, themeans being here a positioning pin, extend on the bottom face of theplate, the pin advantageously being positioned in an oblong hole that isthe machining reference orifice of the bearing;

the force stays 213 d allow downward axial deformation of the powerplate in order to avoid vibration problems, the stays preferentiallyhaving a greater height than the inserts 210 d in order to be sure ofdeforming the plate, the stays extending over the top face of the plate;

the means 214 d of positioning the plate in the dissipator 80, here two,extend over the top face of the plate;

the fixing terminal 215 d makes it possible to fix the plate to thedissipator 80 by means of a nut, and is connected to the negative powertrack B−, which effects an earthing of the dissipator;

the electrical insert 216 d is intended to be assembled with theterminal 215 d on the track 222 d, the track thus being sandwiched bythe insert and the terminal, which thus avoids difficult welding to beperformed between the dissipator, which is preferentially made from castaluminum, and the copper power track;

the power connector 219 d comprises a negative track B+ and a positivetrack B+;

the power terminals 217 d issuing from a positive track B+ are here inan L shape and have an axial tongue, i.e. perpendicular to the plane ofthe power interconnection piece 21 and projecting beyond the planeupwards; the terminals are not overmolded to allow connection with theend of the positive electrical conductor 103 (B+) of an electronicmodule, the terminals extending towards the external periphery of thesignal interconnection piece 22;

the means 218 d of protecting the positive power terminals 217 d protectagainst short-circuits and salt spray in particular;

the positive 221d (B+) and negative 222 d (B−) tracks are molded on inplastic 213 for example, tracks that can be seen in FIG. 14C. The tracksare visible on the power connector 219 d, which allows the fitting ofthe client power connector to make the electrical connections betweenthe connector and the tracks;

the terminal 220 d connecting to the client connector connected to thebattery, the terminal making it possible to effect a pressing betweenthe tracks 221 d and 222 d and the tracks of the client power connectorso that the current can be established correctly between the battery andthe machine; and

a mechanical connection orifice 220 e for a screw, thus avoiding thetransmission of the mechanical stresses on overmolding when the clientpower connector is fixed to the connecting terminal 220 d.

Preferentially, in a variant embodiment, as depicted in FIG. 14E, theovermolding 213 of the power interconnection piece 21 covers the airoutlet openings of the bearing (as far as the outside diameter of thebearing) so as to guide the discharged air in order to reduce a radiallooping back of the air towards the inside of the machine. Thus the saidovermolding comprises a covering collar 213 z shown in FIG. 14E.

Thus the power plate has the advantages of:

-   -   having a single track without overlap, the track making it        possible to effect easier molding and positioning;    -   being fixed under the dissipator 80 and therefore being        separated by a mass from the signal interconnection piece 22, so        that the power signal B+ does not interfere with the signals        from the signal interconnection piece 22;    -   a saving in axial size since the power interconnection piece 21        is positioned in the space necessary for the fins of the        dissipator; and    -   enabling the dissipator to be an isolated mass (with respect to        that of the bearing) or not, and therefore a different mass from        that of the bearing, thus avoiding interference of the on-board        system during starting in particular.

It will be noted that, by virtue of the presence of the powerinterconnection piece 21, there is a large cross-section of copper forconveying the power necessary to the functioning of the machine (150A inalternator mode, 600A on starting) unlike a solution in which the powertracks are integrated in a band also comprising the electronic powermodules.

According to a first non-limitative embodiment, the cover 70 asillustrated in FIGS. 15A to 15C comprises:

-   -   positive 71 (B+) and negative 72 (B−) power tracks;    -   two openings 74 for effecting welding of the power tracks 71, 72        with the corresponding tracks of the power interconnection piece        21;    -   signal tracks 75 affording a connection between the modules and        signal connections 76;    -   signal connections 76;    -   grooves or orifices 77 for positive location; and    -   fixing orifices for fixing screws or nuts 78 for example.

The elements of the cover are described in detail below.

The power tracks 71, 72 are intended to electrically connect the powerinterconnection tracks 212, 211 of the power interconnection piece 21providing the connection between the client power connector of the motorvehicle. The power tracks 71, 72 are molded on in the cover 70 and laserwelded to the two power interconnection tracks 212, 211 of the powerinterconnection piece 21. The electrical connections are made betweenthese two elements, for example through the opening 74 provided for thispurpose. The electrical connections can be made by welding, inparticular by laser welding or weld-brazing, as well as by brazing or bymechanical contact. In the latter case, the mechanical contact isobtained for example by fixing screws for the cover 70 exerting apressure on the tracks.

The signal connections 76 afford a dialogue with the other electronicboxes of the vehicle. These connections comprise signal tracks 75integrated in the cover 70 and connected on the one hand to the controlmodule 30 and at the other end to the client signal connector (notshown). The client signal connector comprises a cable for connection toa control means such as for example a computer controlling variousfunctions of the vehicles such as for example the management of therotary electrical machine according to its generator or motor functions.

The grooves or orifices for positive location 77 make it possible toposition the cover 70 correctly on the guides 107 of the control module30. The grooves or orifices thus engage with guides 107 of the controlmodule 30.

According to a second non-limitative preferential embodiment,illustrated in FIG. 16, the cover comprises:

-   -   openings 79 intended to receive fixing means such as studs in        place of screws.

It also comprises the following elements described in the firstembodiment:

-   -   the power tracks 71, 72;    -   the element 73 for connection to the on-board system;    -   the two openings 74;    -   the signal track 75;    -   the signal connections 76; and    -   the grooves or orifices 77 for positive location.

It should be noted that the cover 70 as described in the two embodimentsis intended to be a part specific to each client because of the specificlocation and the type of client connector or connectors used.

According to a third non-limitative preferential embodiment, illustratedin FIGS. 17A and 17B, the cover is a simple cover that comprises solelyfixing clips 791 for the cover fitting on studs 226 g of the signalinterconnection piece 22 fixing the assembly. It no longer comprises anytrack or connector. There is only plastics material.

After having seen all the elements that cooperate with the electronicmodules, we describe below their assembly.

As will be seen in detail below, the electronic modules are fixed to therear bearing of the machine in several ways:

-   -   either on the bearing directly (dissipator bearing with fins or        water integrating or not heat pipes); or    -   on a non-integrated dissipator (with fins or water integrating        or not heat pipes).

According to a first method of assembling the modules, an electronicmodule interfaces with the following elements:

-   -   a dissipator bearing 60;    -   a signal interconnection piece 22 according to the first or        second embodiments;    -   a power interconnection piece 21 according to the first or        second embodiments; and    -   a cover 70 according to the first or second embodiments.

Thus the 1^(st) method of assembling all the parts described above iseffected in the following manner.

In a first step 1), the electronic module or modules are mounted on thedissipator bearing 60.

The positioning of each module on the dissipator bearing 60 isfacilitated by the two positioning pins 109 a, 109 b, which will besituated opposite each orifice 609 a, 609 b of the correspondingdissipator bearing 60.

The modules are fixed to the dissipator bearing 60 on the one hand bymeans of an adhesive, for example with glass balls, and on the otherhand mechanically in two different ways.

According to a first non-limitative way, illustrated in FIG. 18, each ofthe modules is fixed by three studs 113. The three studs are inserted inthe corresponding orifices 608 in the bearing. FIG. 18 shows theassembly of five modules, three power modules 20, a control module 30and an excitation module 40.

According to a second non-limitative preferential way, illustrated inFIG. 24, the fixing is effected by means of:

-   -   three studs 226 g that are put in place after the installation        of the signal interconnection piece 22 and that are inserted in        the corresponding orifices 681, 682, 683 in the dissipator        bearing 60, and    -   a screw 226 v that is inserted in the associated orifice 684 in        the bearing.

FIG. 23 shows the assembly of four modules, three electronic modules 10,one control/excitation module.

For the two ways, all the modules are preferentially arranged in thesame plane perpendicular to the rotation axis of the rotor of theelectrical machine, just like the power tracks and the signalconnections, in order to facilitate their assembly.

However, in a variant of what is presented in the previous figures, themodules can be disposed on different planes.

In a second step 2), the signal interconnection piece 22 is mounted onthe electronic modules. Because of this, the plate is as close aspossible to the modules in order to reduce the length of the signalconnections as far as possible and to prevent plugging problems. In thisway, the signal connection element 106 of the modules are short; thustheir deformation is better controlled (they are less deformable), theconnections preferably being flexible.

The signal interconnection piece 22 is fixed to the module/bearingassembly in two different ways corresponding to the two ways of fixingthe modules to the bearing as described previously.

According to a first non-limitative way, illustrated in FIG. 19, thesignal interconnection piece 22 is positioned by means of thepositioning studs 224, which are positioned opposite the positioningorifices 601 a and 601 b of the bearing. Thus, by virtue of thispositioning:

-   -   the connection recesses 221 a are placed opposite the signal        tongues 106 a of the modules;    -   the connection recesses 221 b are placed opposite the signal        tongues 106 b of the modules; and    -   the fixing lugs 222 are placed opposite the studs 113 of the        electronic module 10.

Next, after pressing, the signal tongues 106 a are inserted in theinterconnection orifices 2210 of the metal signal tracks TS, the signaltongues 106 b are inserted in the interconnection orifices 2211 of themetal signal tracks TS, and the lugs 222 are fixed to the studs 113.

According to a second non-limitative preferential way, illustrated inFIG. 24, the signal interconnection piece 22 is positioned on themodules by means of the positioning pins 224, which are positionedopposite the positioning orifices 610 a and 610 b of the bearing. Thus,by virtue of this positioning:

-   -   the connection recesses 221 a are placed opposite the signal        tongues 106 a of the modules;    -   the connection recesses 221 b are placed opposite the signal        tongues 106 b of the modules;    -   the stays 225 a and 225 b are placed opposite the support zones        114 of the modules; and    -   the inserts 226 are placed opposite the corresponding orifices        681 to 684 in the bearing.

Next, after pressing, the signal connection elements 106 are inserted inthe corresponding recesses 221, the stays 225 bearing on the supportzones 114 of the modules.

The studs 226 g, which are inserted in the recesses 221 in the signalinterconnection piece 22 and orifices 681, 682, 683 of the dissipatorbearing 60, are then fixed. The studs bear on the plate and consequentlyon the plate/modules/bearing assembly so as to afford better mechanicalstrength. In the same way, the screw 226 v is screwed into therespective corresponding insert 226 and 684 in the signalinterconnection piece 22 and dissioator bearing 60.

Thus the signal interconnection piece 22 is produced so as to exert apressure on the power module 20 and the other modules 30, 40 in order toguarantee their holding throughout the life of the rotary electricalmachine.

In a non-limitative embodiment, the material of the plate is PPS(phenylene polysulphide) plastic containing glass fibers.

Thus, according to these two ways, the signal plate is deformed in orderto exert a pressure on the modules, the deformation preferably beingapproximately 0.3 mm. In this way, the detachment of the modules isprevented and stresses on the welds of the tongues are avoided.

In a third step 3), the power interconnection piece 21 is mounted on thebearing/modules/signal plate assembly. The power interconnection piece21 is fixed above the signal interconnection piece 22.

The power interconnection piece 21 is fixed in two different ways.

According to a first non-limitative way, illustrated in FIG. 20, thepower interconnection piece 21 is placed on the signal interconnectionpiece 22 so that:

-   -   the fixing lugs 215 are placed opposite the studs 113 of the        signal interconnection piece 22, the studs making it possible to        position the power interconnection piece 21; and    -   the power terminals 2120, 2110 are placed opposite the        corresponding tracks of the electrical conductors 103, 104.

In the case of a brush holder, it is positioned so that it is insertedin the recess 605 and the brush cage protector in the recess 603 of thebearing.

Next, after pressing, the fixing lugs 215 are fixed on the studs 113,the power terminals 2120, 2110 bear respectively on the ends of theelectrical conductors 103, 104 of the modules.

According to a second non-limitative preferential way, illustrated inFIG. 25, the power interconnection piece 21 is placed on the signalinterconnection piece 22 so that:

-   -   the inserts 219 are placed opposite the studs 226 g, the        orifices and studs serving as a positive location device; and    -   the lug 218 is placed opposite the holding clip 227 of the        signal interconnection piece 22.

Next, after pressing, the inserts 219 are inserted on the studs 226 gand the lug 218 snaps in the holding clip 227, and

-   -   the orifice 219 c is placed opposite a third stud 226 g.

In a last step, the cover 70 is mounted on the assembly. In this way,the cover 70 forms a shroud for the rear bearing of the machine.

The cover 70 is fixed in two different ways.

According to a first non-limitative way, illustrated in FIGS. 21 and 22,the cover 70 is placed on the power interconnection piece 21 so that thegrooves 77 of the cover are situated opposite the guides 107 of thecontrol module 30. These guides and grooves serve as a positive locationdevice.

Next, after pressing, the grooves are inserted in the guides so that:

-   -   contact is established between the signal tracks 75 of the cover        70 and the signal tongues 106 c of the control module 30; and    -   contact is established between the power tracks 71 (B+), 72 (B−)        of the cover and respectively the power interconnection tracks        212, 211 of the power interconnection piece 21.

Finally, after installation of the cover, the electrical connection ismade between the power tracks 71, 72 of the cover and the powerinterconnection tracks 212, 211 by laser welding via the openings 74.

The cover is fixed by three screws or nuts 78.

According to a second non-limitative preferential way, illustrated inFIG. 26, the cover 70 is placed on the power interconnection piece 21 inthe same way as the first way with a view to establishing the electricalcontacts. In addition, the openings 79 are placed above the three studs226 g that fix the electronic assembly.

Next, after pressing, the cover 70 is fixed by means of the studs to theelectronic assembly (bearing/modules/interconnection plates).

In this case, the cover 70 bears on all the elements of the arrangementand thus ensures sufficiently strong support in order both to immobilizethe power interconnection piece 21 on the dissipator bearing and toprovide the necessary electrical contacts.

Thus, as can be seen, according to this first assembly mode, theelectronic modules 10, the signal interconnection piece 22, the powerinterconnection piece 21 and the dissipator occupy respectively first,second, third and fourth planes all parallel to one another, and theplanes are superimposed in the following order starting from the planeclosest to the rear bearing of the machine:

-   -   fourth plane;    -   first plane;    -   second plane; and    -   third plane.

Thus the power interconnection piece 21 is independent of the electronicmodules and is connected to the modules in particular only by its powerelectrical terminals.

The same applies to the signal interconnection piece 22, which isconnected to the modules in particular only by its signal connectionelement 106.

According to a second module assembly mode, or arrangement, anelectronic module interfaces with the following elements:

-   -   a dissipator 80;    -   a signal interconnection piece 22 according to the third        embodiment;    -   a power interconnection piece 21 according to the third        embodiment; and    -   a cover 70, according to the third embodiment.

Thus the second method of assembling all the parts described above iseffected as follows.

It should be noted that, in the example taken for this assembly method,there exist four modules that are fixed to the dissipator 80. Threepower modules 20 and one control module 30.

In a first step 1), illustrated in FIG. 27A the modules are positionedon the top face of the dissipator 80 so as to fix them.

The positioning takes place by means of the positioning pins 109 a and109 b, which are placed opposite the orifices 810 of the dissipator 80,and during the positioning the insert 120 of each module comes to bepositioned opposite each associated orifice 804 in the dissipator 80.

Subsequently the fixing is carried out by means of:

-   -   screws 1150 that are inserted in the fixing orifices 115 of the        modules and the corresponding orifices 804 of the dissipator 80.        These fixing screws also make it possible to connect the modules        to earth via the insert 120; and    -   the signal connector 116 of the control module 30, which is        screwed into the associated orifice 807 of the dissipator, by        means of a via screw.

During assembly,

-   -   the electrical protection means 126 of the modules are inserted        in the recesses 809 of the dissipator provided for this purpose.

In addition, the modules are also bonded to the dissipator 80 by meansof an adhesive, such as a glass ball adhesive.

It should be noted that, prior to the fixing of the control module 30 tothe dissipator 80, the brush holder 50 was fixed to the module by meansof the screw 117 a provided for this purpose. In another variant, it ispossible to fix it after the installation of the control module 30 onthe dissipator 80.

In a second step 2), illustrated in FIG. 28, the power interconnectionpiece 21 is positioned on the bottom face of the dissipator so as to fixthe power interconnection piece 21 to the dissipator 80.

The positioning is effected by means of:

-   -   means 214 d of positioning the power interconnection piece 21        that come opposite the associated mechanical positioning        orifices 808 in the dissipator; and    -   the fixing terminal 215 d, which comes opposite the electrical        connection orifice 805.

The fixing of the power interconnection piece 21 on the dissipator 80 iseffected by means of:

-   -   the two positioning means 214, which are placed in the        corresponding mechanical positioning orifices 808 in the        dissipator;    -   the fixing terminal 215 d, which is plugged into the electrical        connection orifice 805; and    -   the four force stays 213 d, which are placed opposite the        corresponding support zones 814 of the dissipator.

During assembly,

-   -   phase protection means 211 d are integrated in the recesses 812        provided for this purpose in the dissipator.

Thus, as can be seen in FIG. 28:

-   -   the means 221 d will protect the phase tongues of the stator;    -   the axial tongues of the fixing terminals 215 d are then        opposite the corresponding positive electrical conductor 103        (B+) of each electronic module 10, which will make it possible        to establish an electrical connection between the electrical        conductor 103 and the positive track 221 d (B+) of the power        interconnection piece 21; and    -   the electrical insert 216 d integrated in the terminal 215 d        makes it possible to earth the dissipator 80.

In a third step 3), illustrated in FIG. 29, the signal interconnectionpiece 22 is positioned on the electronic modules 10 so as to fix it.

It should be noted that the signal interconnection piece 22 ispre-positioned (pre-guided) by virtue of two protection pins or guides107 of two electronic modules 10, the pins being the furthest away fromeach other in order to pre-guide well.

The positioning is effected by means of:

-   -   the two hollowed-out protuberances 230 serving for pre-guidance        and which are pre-positioned on two positioning pins or guides        107 belonging to electronic modules.

Then, subsequently, it is possible to position the signalinterconnection piece 22 by means of the positioning pins 224 in thecorresponding orifices 811 of the dissipator 80.

During assembly, there are:

-   -   the connection recesses 221 a that are placed opposite the        signal tongues 106 a of the modules;    -   the connection recesses 221 b that are placed opposite the        signal tongues 106 b of the modules;    -   the stays 225 a and 225 b that are placed opposite the support        119, 114 respectively of the modules; and    -   the inserts 226 that are placed opposite the corresponding        orifices 806 of the dissipator.

The fixing takes place by means of:

-   -   insulated hollow rivets 2101 d associated with the inserts 210 d        of the power plate. These rivets 2101 d inside the inserts allow        on the one hand an assembly of the signal plate and on the other        hand an insulation of the mass of the dissipator with respect to        the mass of the bearing, and finally the creation of an        electronic sub-assembly (the two plates, the dissipator and the        electronic modules) pre-assembled so that, during assembly on        the bearing, by means of screws or studs, after welding the        signal connection element 106 with the signal interconnection        piece 22, there are no additional forces that would risk        mechanically stressing the welds.

Next, after pressing, the signal connection element 106 are inserted inthe corresponding interconnection orifices 2210, 2211, the stays 225bearing on the support 119, 114 of the modules.

It should also be noted that the housings 231 of the signal platecomprise in the example illustrated in FIG. 29 a capacitor associatedwith each of the power modules 20, which is connected firstly to thepositive electrical conductor 103 (B+) of the associated module andsecondly to the negative electrical conductor 104 (B−) of the associatedmodule.

In addition, preferentially, it is possible to effect a tin or laserwelding, or to deposit a resin plus polymerization in the connectionrecesses 221 a and 221 b of the signal connection element 106 in orderin particular to protect them from salt spray.

In a fourth step 4), illustrated in FIG. 30A, the whole of theelectronics thus obtained are positioned on the rear bearing 90 of themachine.

Fixing takes place by means of:

-   -   four studs 226 g or screws in the rear bearing 90 by means of        the inserts 226 of the signal interconnection piece 22, inserts        210 d of the power interconnection piece 21 and fixing orifice        806 of the corresponding dissipator 80. The studs bear on the        same plate and consequently on the plate/dissipator/bearing        assembly so as to create an electronic assembly on the bearing.        In the same way, the screw 226 v is screwed in the respective        corresponding inserts 226 and 807 of the signal interconnection        piece 22 and dissipator 80.

FIG. 30B is a view in section along the plane X-Y shown in FIG. 30A,showing an entire assembly of the main parts cited above. It shows inparticular:

-   -   the rear bearing 90;    -   the power interconnection piece 21;    -   the dissipator 80;    -   the signal interconnection piece 22;    -   a rivet 2101 d; and    -   a fixing stud 226 g.

It should be noted that, prior to the electronic assembly, the rearbearing 90 of the machine is fixed to the front bearing (not shown) ofthe machine by means of four tie rods in orifices 903, the orificesbeing illustrated in FIG. 30C of the rear bearing 90. The tie rods arethus screwed before the electronic assembly, which makes it possible toposition the phases of the stator in advance and therefore to facilitatethe assembly of the electronic sub-assembly with the phases.

The rear bearing comprises in particular:

-   -   a positioning orifice 901 configured so as to receive the        positioning pin 1151 of the control module 30, which allows        precise positioning of the position sensors with respect to the        bearing; and    -   a referencing orifice 902 in which the pin 212 d of the power        interconnection piece 21 is inserted.

The phase hooks 105 cr are also welded to the phases of the stator(standard wires or using a thimble).

Finally, in a fifth step 5), the plastic cover 70 is put in place bymeans of fixing clips that are snapped onto the studs.

It should be noted that the steps specified above can be performed in adifferent order. For example, the second step can of course be performedbefore the first step (FIG. 27B illustrates this case) or after thethird step.

Thus the second assembly method has the following advantages:

-   -   firstly, the assembly of the entire electronic part (modules,        power and signal plates) takes place outside the rear bearing so        that it is possible to test the electronics before assembly on        the machine; in this way only the electronics that function in        the machine are integrated, which saves time in terms of        process, and makes it possible to have two independent processes        and therefore not to modify the “process” method of standard        machine assembly that already exists;    -   secondly, the assembly of the electronic part can take place        after the assembly of the rear bearing of the machine on the        front bearing, or more particularly after the fitting of the tie        rods fixing the bearings, which will then be covered by the        electronics;    -   thirdly, the performance with regard to thermal cooling is        improved because of the axial air flow added to the radial air        flow. There is a reduction in pressure drops with an axial air        inlet;    -   fourthly, the cover is now no more than a simple plastic cover.        There are no molded-on tracks in the cover, the power tracks and        the signal tracks being integrated respectively in the power        plate and in the control/excitation module, which makes it        possible to limit the number of interconnection welds to be        carried out;    -   fifthly, the earth plane is implemented by the dissipator. There        is therefore a reduction in the resistance and inductance of the        internal power circuit between the client two-phase power        connector and the power module because of the proximity of the        positive-polarity track (B+) of the power interconnection piece        21 to the dissipator mass; and    -   sixthly, the earth plane is implemented by the dissipator, so        that there is a saving in axial space. In this way an existing        part is used for conveying current.

Thus, according to this second assembly method, the electronic modules10, the signal interconnection piece 22, the power interconnection piece21 and the dissipator occupy respectively first, second, third andfourth planes all parallel to one another, and the planes aresuperimposed in the following order, starting from the plane closest tothe rear bearing:

-   -   third plane;    -   fourth plane;    -   first plane; and    -   second plane.

Thus the power interconnection piece 21 is independent of the electronicmodules and is connected to the modules in particular only by itselectrical power terminals.

The same applies to the signal interconnection piece 22, which isconnected to the modules in particular only by its signal connectionelement 106.

Thus all the four parts form an independent electronic sub-assembly of abearing of the machine.

It should be noted that the two assembly methods have the advantage ofusing the maximum surface available on the rear of the machine for themodules by virtue of the stacking of the various elements for the powerand signal interconnections, unlike a solution in which the power andsignal interconnection tracks occupy surface on the rear of the machineto the detriment of the modules.

It should be noted that the signal interconnection piece 22 according tothe various embodiments described above can be used when there is nopower interconnection piece 21. For example with modules themselveseffecting their power interconnection.

As for the power interconnection piece 21 according to the variousembodiments described previously, it can also be used without the signalinterconnection piece 22. For example, with an electronic card PCBeffecting the signal interconnection.

The assembly according to all the embodiments presented above has thefollowing additional advantages:

-   -   it avoids stacking all the tracks on one another, a stack not        being propitious to good holding in position of the tracks;    -   it comprises means of fixing to the dissipator or to the        dissipator bearing that are not concentrated on the periphery of        the dissipator or bearing, so that there exists a distribution        of forces so as to withstand the mechanical vibrations well;    -   it enables the various components (interconnection plates and        modules) to be in different planes and perpendicular to the        rotation axis of the machine, so that it creates more space for        the power tracks, which gives rise to a reduction in the        resistivity of the tracks. Thus this assembly makes it possible        to convey higher power; and    -   it makes it possible to use in an optimum fashion the space        available for the electronic modules on the rear bearing of the        machine, the various components (interconnection plates and        modules) being on different planes and perpendicular to the        rotation axis of the machine.

While the form of apparatus herein described constitutes a preferredembodiment of this invention, it is to be understood that the inventionis not limited to this precise form of apparatus, and that changes maybe made therein without departing from the scope of the invention whichis defined in the appended claims.

1. A power interconnection piece for a rotary electrical machine,wherein said power interconnection piece comprises at least one powertrack provided with electrical power terminals to cooperate with a powertrack of at least one electronic module so as to distribute electricalpower to said electronic module, said electronic module being integratedon said rotary electrical machine; wherein said power interconnectionpiece is configured so as to be placed on the bottom face of adissipater; wherein said power interconnection piece also comprises atleast one force stay for axial deformation of said power interconnectionpiece, said at least one force stay preferably having a greater heightthan the insert.
 2. The power interconnection piece according to claim1, wherein said power interconnection piece comprises a base plate madefrom insulating material that at least partially overmolds said powertrack.
 3. The power interconnection piece according to claim 2, whereinsaid base plate comprises at least one recess for an electricalconnection of a power interconnection track with a cover.
 4. The powerinterconnection piece according to claim 1, wherein said powerinterconnection piece is configured so as to be placed on a planedifferent from that of the electronic module, preferably above theelectronic module.
 5. The power interconnection piece according to claim1, wherein said power terminals extend towards the external periphery ofsaid power interconnection piece.
 6. The power interconnection pieceaccording to claim 1, wherein said power terminals comprise curved freeends.
 7. The power interconnection piece according to claim 1, whereinsaid power track is flat.
 8. The power interconnection piece accordingto claim 1, wherein said power interconnection piece comprises at leastone positive power interconnection track and at least one negative powerinterconnection track.
 9. The power interconnection piece according toclaim 1, wherein said power interconnection piece also comprises fixingdevices for fixing to an electronic module, said fixing devicesextending radially on the external periphery of said powerinterconnection piece.
 10. The power interconnection piece according toclaim 1, wherein said power interconnection piece also comprises devicesfor pre-assembly on a signal interconnection piece, said signalinterconnection piece conveying control signals between electronicmodules.
 11. The power interconnection piece according to claim 1,wherein said power interconnection piece also comprises inserts forreceiving fixing means for fixing on said rotary electrical machine. 12.The power interconnection piece according to claim 1, wherein said powerinterconnection piece also comprises support devices for supporting saidpower interconnection piece on a dissipator of said rotary electricalmachine during assembly.
 13. The power interconnection piece accordingto claim 1, wherein said power interconnection piece comprises a centralrecess for the insertion of a brush holder.
 14. The powerinterconnection piece according to claim 1, wherein said powerinterconnection piece also comprises at least one insert for receiving ahollow rivet and effecting a pre-assembly with an electronic module anda signal interconnection piece and a dissipator.
 15. The powerinterconnection piece according to claim 1, wherein it also comprisesmeans of protecting stator phases of said rotary electrical machine. 16.The power interconnection piece according to claim 1, wherein it alsocomprises means of positioning on the bearing of said rotary electricalmachine, said means extending over a bottom face of said powerinterconnection piece, and preferably other devices for positioning saidpower interconnection piece on a dissipator of said rotary electricalmachine.
 17. The power interconnection piece according claim 1, whereinsaid power interconnection piece also comprises a metal insert so as toeffect an electrical connection with a negative power track.
 18. Thepower interconnection piece according to claim 1, wherein the powerinterconnection terminals issue from a positive power track.
 19. Thepower interconnection piece according to claim 1, wherein the electricalinterconnection terminals are axial tongues projecting beyond the topface of said power interconnection piece.
 20. The power interconnectionpiece according to claim 1, wherein said power interconnection piecealso comprises a power connector in which positive and negative powertracks are inserted in a visible fashion.
 21. The power interconnectionpiece according to claim 1, wherein said power interconnection piecealso comprises a terminal for mechanical connection to a clientconnector.
 22. The power interconnection piece according to claim 1,wherein said power interconnection piece also comprises a collarintended to cover air outlet openings in the bearing of said rotaryelectrical machine so as to guide the outlet air and attenuate a loopingof air.